Copyright Undertaking This thesis is protected by copyright, with all rights reserved. By reading and using the thesis, the reader understands and agrees to the following terms: 1. The reader will abide by the rules and legal ordinances governing copyright regarding the use of the thesis. 2. The reader will use the thesis for the purpose of research or private study only and not for distribution or further reproduction or any other purpose. 3. The reader agrees to indemnify and hold the University harmless from and against any loss, damage, cost, liability or expenses arising from copyright infringement or unauthorized usage. IMPORTANT If you have reasons to believe that any materials in this thesis are deemed not suitable to be distributed in this form, or a copyright owner having difficulty with the material being included in our database, please contact [email protected] providing details. The Library will look into your claim and consider taking remedial action upon receipt of the written requests. Pao Yue-kong Library, The Hong Kong Polytechnic University, Hung Hom, Kowloon, Hong Kong http://www.lib.polyu.edu.hk CREATION OF 3D DIGITAL PRINTED FASHION PROTOTYPE WITH INNOVATIVE SURFACE TEXTURE CHAN HIU SEN PhD The Hong Kong Polytechnic University 2019 The Hong Kong Polytechnic University Institute of Textiles and Clothing CREATION OF 3D DIGITAL PRINTED FASHION PROTOTYPE WITH INNOVATIVE SURFACE TEXTURE CHAN HIU SEN A thesis submitted in partial fulfillment of the requirements for the degree of Doctor of Philosophy June 2018 CERTIFICATE OF ORIGINALITY I hereby declare that this thesis is my own work and that, to the best of my knowledge and belief, it reproduces no material previously published or written, nor material that has been accepted for the award of any other degree or diploma, except where due acknowledgement has been made in the text. ___________________________________ CHAN Hiu Sen i ABSTRACT Recent studies have indicated that three-dimensional printing technology benefits the design process and is defined as a breakthrough in the manufacturing process. Three-dimensional printing has come into wide use in different industries as well as fashion industry. Fashion or textile designers adopt 3D printing technology as their creative design tools, such as creating 3D printed garments, 3D printed fabrics or fashion accessories. 3D printers can practically create anything, hence they give designers wide imaginary space and produce creative products. It can be predicted that 3D printing technology will be rapidly applied and play an important role in fashion industries in the future. This research study is practice-based, which combines the theories of 3D printing technologies, practical concept and physical prototype development of 3D printed fashion with innovative surface texture that could be able to apply in current fashion market. The aim of this study is to develop a high- value fashion prototype with an innovative coloured surface texture by using 3D printing technology, based on a theoretical design process model. The research was mainly divided into four stages: research stage, development of the design process model, development and evaluation of the initial prototypes, and detailed design stage. A final 3D printed fashion prototype with innovative texture was then created according to the developed design process model. The knowledge of aesthetic and technical aspects of ii 3D printing technology and a specific design process model were integrated in this study; thus, both theoretical and practical contribute to the field of 3D printed fashion design to illustrate the innovative design process for 3D printed fashion. The developed theoretical design process model for 3D- printing-based fashion with innovative surface texture can be implemented to contemporary fashion and the high value 3D printed prototype can enhance novelty in high fashion and inspire fashion designers to create successful 3D printed designs for the market. iii PUBLICATIONS GENERATED FROM THIS STUDY Conference Paper Chan, I., Au, J., Ho, C.P. & Lam, J. Development of Theoretical Process Model for 3D Printed Fashion Prototypes with Innovative Surface Texture. Proceedings of the 14th Asian Textile Conference, The Hong Kong Polytechnic University, Hong Kong. Date: 27 – 30 Jun 2017. Chan, I., Au, J., Ho, C.P. & Lam, J. Design and Development of Multi- coloured 3D Printed Fashion Garment with Innovative Surface Texture. Proceedings of the International Conference on Clothing and Textiles 2018, Seoul. Date: 26 May 2018. Remark: Winner of 2018 ICCT Graduate Student Research Competition. Exhibition Chan, I., Au, J., Ho, C.P. & Lam, J. Creation of 3D Digital Printed Prototype with Innovative Surface Texture. Opening Ceremony of the University Research Facility in 3D Printing, The Hong Kong Polytechnic University, Hong Kong. Date: 19 Apr 2017. Chan, I., Au, J., Ho, C.P. & Lam, J. 3D Multi-coloured Printed Fashion. PolyU 80th Anniversary Open Day: PolyU Research Showcase: Human- centered Innovation (Design & Textile), The Hong Kong Polytechnic University, Hong Kong. Date: 2 – 3 Dec 2017. iv Chan, I., Au, J., Ho, C.P. & Lam, J. 3D Multi-coloured Printed Bottom Dress. PolyU 80th Anniversary Open Day: PolyU IC 3D Printing Lab Tour Guide Showcase, The Hong Kong Polytechnic University, Hong Kong. Date: 2 – 3 Dec 2017. Invited Speech Chan, I., Au, J., Ho, C.P. & Lam, J. Development of 3D Printed Fashion Prototype with Innovative Surface Texture. Fashion Business Seminar Series 2018: Introduction to 3D Printing - Future of the Fashion Industry? The Hong Kong Polytechnic University, Hong Kong. Date: 6 Feb 2018. v ACKNOWLEDGEMENTS I would like to express my appreciation to my chief supervisor Dr. Joe Au for his valuable guidance and suggestions throughout the research. Without his expertise and support, I would not have been able to complete this thesis. Secondly, I would like to acknowledge a studentship received from The Hong Kong Polytechnic University Postgraduate Research Grant and offer my thanks to the material sponsorship from Stratasys AP Limited. I would also like to thank Ir. Sidney Wong and Mr. Frankie Chan of Industrial Centre of The Hong Kong Polytechnic University for their technical assistances. Last but not least, I would like to express my thanks to my mom for her support and encouragement throughout my study. vi TABLE OF CONTENTS CERTIFICATE OF ORIGINALITY ........................................................ i ABSTRACT .............................................................................................. ii PUBLICATIONS GENERATED FROM THIS STUDY ....................... iv ACKNOWLEDGEMENTS .................................................................... vi TABLE OF CONTENTS ........................................................................ vii LIST OF FIGURES ............................................................................... xvi LIST OF TABLES ...................................................................................xx CHAPTER 1: INTRODUCTION ............................................................ 1 1.1 Background of Study ........................................................................ 1 1.1.1 Importance of 3D Printed Fashion and Textile Design ................ 2 1.1.2 Definition of 3D Printing ........................................................... 3 1.1.3 Definition of Surface Texture ..................................................... 3 1.2 Problem Statement ............................................................................ 4 1.3 Objectives ......................................................................................... 5 1.4 Research Methodology ..................................................................... 6 1.4.1 Research Review ........................................................................ 6 1.4.2 Development of Design Process Model ...................................... 7 1.4.3 Development and Evaluation of Initial Prototypes ...................... 7 1.4.4 Development of Final Prototype ................................................. 7 1.5 Significance of Study ........................................................................ 8 vii CHAPTER 2: LITERATURE REVIEW ................................................10 2.1 Introduction .................................................................................... 10 2.2 Introduction to 3D Printing ............................................................. 10 2.2.1 Historical Background of 3D Printing .......................................11 2.2.2 Significance of 3D Printing Technologies ................................. 12 2.2.2.1 Customisation ................................................................... 12 2.2.2.2 Energy Savings.................................................................. 13 2.3 Three-Dimensional Printing Methods.............................................. 13 2.3.1 Photopolymerisation ................................................................ 13 2.3.1.1 Stereolithography .............................................................. 14 2.3.2 Extrusion Deposition ................................................................ 14 2.3.3 Material Jetting ........................................................................ 15 2.3.4 Granular Material Binding ....................................................... 15 2.3.5 Binder Jetting ........................................................................... 16 2.3.6 Directed Energy